| [ Total Views: 7622 | Total Replies: 95 | Thread Id: 98935 ] |
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 matberry
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| posted on September 24th, 2012 at 10:00 PM |
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Things not to do to your VW
I would love to name and shame but we all know that's not such a good idea. I see this type of thing SO often it makes me very sad, so I feel it
necessary to share some of these experiences so that people understand that new doesn't always mean good, and just because someone says 'it's all
been done' doesn't mean take anything for granted.
For the first example I will use the most recent.
This is a performance VW engine built by a professional VW specialist. It cost a lot of money and the design brief was for a reliable, torquey engine
that will be understressed and live a long life.
The owner was actually very lucky as it caught fire due to carburettor issues that actually saved a catastrophic failure.
So you're aware, it's not just the engine builder at fault here, also with something to answer for is the shop selling the parts. Here the guy
behind the counter actually advised against some of the parts manufactures specifications claiming he knew better. This advice was also partly to
blame for some of the premature failures inside the engine.
Firstly a brief engine overview
2276cc 82mm Scat crankshaft x 94mm Mahle piston & barrel kit
New aluminium high roof shuffle pinned engine block
New 043 VW heads
Dual 36mm Dellorto carbs
to date this engine has done around 5000km and been 'maintained' by the builder.....
Here's a pic of what came out of the carby accelerator pump. The globs of sh1t on the bench and screw driver were solid behind the diaphram and
completely blocking the circuit passages and one way valves.
The next beauty is swarf, that's right, metal shavings that were in the oil passages, this pic is the now blank one end oil pump outlet gallery in
the case where the swarf has accumulated
This one is a ripper...here the dude decided to put the bigger cam bearing in the #3 bearing location, but forgot to mod the bearing for the oil
drain, therefore compromising the bearing
More tomorrow
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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 66deluxe
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| posted on September 24th, 2012 at 10:25 PM |
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Oh it gets better people. I saw this engine.
This is my Volkswagen, there are many like it, but this one is mine. Without me my Volkswagen is useless, without my Volkswagen, I am useless.
61 Karmann Ghia 2110cc type1 w Los Panchito's
66 Deluxe Beetle 2270 type 4
10 Subaru WRX Impreza
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 barls
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| posted on September 24th, 2012 at 10:29 PM |
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looks like its up there with the infamous red silicon engine builder for quality.
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psimitar
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| posted on September 24th, 2012 at 10:42 PM |
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Dude, my mother-in-laws Mazda 3 MP23 is 6 years old and been regularly serviced by the main dealer. I've been driving it lately and found the auto
box to be rather notchy and jerky so thought I'd check the oil. Overfilled and blacker than the black stump. Oh how very well serviced.
I feel sorry for people that know nothing about cars cos in my experience you get ripped off left, right and centre when not in the know yet you
don't even know you're being screwed over. 
madness is in the eye of the beholder  |
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vassy66T1
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| posted on September 25th, 2012 at 05:54 AM |
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Nothing worse than shelling out $ and getting $h!t
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HappyDaze
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| posted on September 25th, 2012 at 06:55 AM |
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That is disgusting. Fixing other peoples bodgie work is more difficult than doing it right in the first place.
Being a panel-beater by trade, I have had to re-do some shocking repairs in the past, and I know exactly how you must feel, Matt. Hope it all turns
out O.K.
I'd rather wear a Beetle out by racing it than by polishing it!
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Governor
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| posted on September 25th, 2012 at 07:31 AM |
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Good post.
Who was the builder, you know its the question everyone is wanting to ask?
I am just relieved that I have a good engine builder.
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vwo60
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| posted on September 25th, 2012 at 10:34 AM |
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This is one reason that i do all my own work, i had a later box fitted to a 60 beetle by a repairer who i thought was alright until it broke clutch
cables all the time. when i had a look at it the bowden tube was too long, when i approched him he just said bad luck, basicly piss off, had to
shorten the clutch tube were it come's out of the tunnel next to the gearbox, have not broken a cable since. I make certain that i tell every body to
steer clear of him all the time.
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Blue65
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| posted on September 25th, 2012 at 01:45 PM |
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| Quote: | Originally
posted by vwo60
This is one reason that i do all my own work, i had a later box fitted to a 60 beetle by a repairer who i thought was alright until it broke clutch
cables all the time. when i had a look at it the bowden tube was too long, when i approched him he just said bad luck, basicly piss off, had to
shorten the clutch tube were it come's out of the tunnel next to the gearbox, have not broken a cable since. I make certain that i tell every body to
steer clear of him all the time.
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If you don't mind - can you tell me who it is so that I can stay away from him too? I'm in Victoria.
______________________
Owner of a 1964 VW Beetle, 1641cc engine, etc..
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nils
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| posted on September 25th, 2012 at 07:16 PM |
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My brother got caught by one of these "pro" engine builders aswell. $6k for less than 5000km of engine life. The flywheel and gland nut was glued in
because of a poor fit or quality. the flywheel all but cam off destroying the rear main seal, mating surfaces and rear bearing. after pulling the
engine down we found alot of the same evidence you are posting above. not a simple mistake, but just hands down lack of concern for the finished
product
might be the same guy?
Quit calling rust patina
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matberry
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| posted on September 25th, 2012 at 07:40 PM |
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Thanks for your comments to this thread. feel free to add your stories of woe ;(
One thing that worries me with this one, is that this is a combination of shops. The original builder, the parts supplier AND the next workshop that
also had a go at it. All been around VWs for a very long time !!!!
This is the way the lower tinware was 'modified' to clear the exhaust.......shame there was no concern for the damaged pushrod tubes that were now
bent and rubbing on the pushrods
not just one side either......this guy is good 
Here at the very top of the pic you can see where the full flow feed line fitting must have cracked the case during fitting or tapping the thread so
he had the case welded
The missing bolt on the top case join was exactly that.......missing
Similar to the sump stud that was too short so .....hey, 5 nuts will be more than enough.....surely????
last tonight is this beauty....how many threads do you really need to hold the head on?????
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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vlad01
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| posted on September 25th, 2012 at 09:21 PM |
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wow! great attention to detail. I wish I could build engines like that good.
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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psimitar
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| posted on September 25th, 2012 at 09:52 PM |
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WHY is there a jubilee clip on the oil pick up pipe?
Little off subject maybe but quality of parts supplied these days. For instance, brand new Beetle sloping headlight seals been on for a year and most
of that under a house and they have cracked on the outside edge already.
I have no trust in any tradie in Brissy due to the shit jobs I've come across later on.
Grandma's Corolla we bought from her had been regularly serviced and maintained by her 'trusted' local garage. She had to give me $1200 to buy the
parts required to get it thru the roadworthy cert for change of ownership. If the work had been done by a garage it would have cost the price of the
car to fix it all.
Oh, and they tried to change the cam belt, maybe, but couldn't get the crank pulley off so when putting the camcover back on instead of pay $20 for a
new gasket they used hardening gasket sealant under a rock hard rubber gasket. Hence the engine was covered in years of caked on oily crap.
Oh, I so could go on but WTF happened to the old days when a bad tradie was in the minority?
madness is in the eye of the beholder |
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smithy68
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| posted on September 25th, 2012 at 11:58 PM |
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Yea Iam interested in the hose clamp on the pickup as well ?
How much did the original build cost this customer?
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matberry
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| posted on September 26th, 2012 at 07:49 AM |
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Hose clamp is the cheapo way of securing the oil pickup extension for the deep sump. Should be welded although a sealed hose clamp job when using the
og strainer will suffice. This one though was quite loose, so much so I took video of it coming off without loosening the clamp. 
Original build cost......$10k 
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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vw54
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| posted on September 26th, 2012 at 07:54 AM |
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nice pics
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vwo60
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| posted on September 26th, 2012 at 07:58 AM |
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Great quatity of work, must have trained with the best. i like the nut, australian standard is three threads past the nut.
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Governor
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| posted on September 26th, 2012 at 08:24 AM |
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The hose clamp is usually supplied in the extended sump kit, but I have never seen anyone actually use it before?
The engines I have seen built are always welded on.
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psimitar
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| posted on September 26th, 2012 at 07:21 PM |
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and how much of that $10k was parts, and of what quality?
madness is in the eye of the beholder |
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AA003
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| posted on September 26th, 2012 at 07:38 PM |
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It just shows what a waste of space our education system is! (Tafe, Universities etc)
I read it on samba, so it must be correct.
Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!
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coletrickle
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| posted on September 26th, 2012 at 08:20 PM |
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I miss being up at your joint matty working on volksies, But I definatly don't miss this kind of shit!One thing is for sure I've forgotten how may
times I heard people say I've been to X,Y and Z shops my shits still all jacked up and now I've got no money to fix it properly?Do people ever go
back and lay this kind of crap on the table and ask for an explination?I had bad service at a vetinary surgery recently went back saw the owner told
him I'd park out front with a sign outlining my problems for as long as it took and that was over $200 and he saw the point I was making,for $15,000
Youll wish you never heard of me.
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Stanley
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| posted on September 26th, 2012 at 08:39 PM |
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I think the most important thing missing here other than workmanship or quality is pride.
How can a business take pride in this type of work. Shame on you. How would you like it if someone did this to your kid or mum.
Good post Matt
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vlad01
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| posted on September 26th, 2012 at 09:09 PM |
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| Quote: | Originally
posted by vwo60
Great quatity of work, must have trained with the best. i like the nut, australian standard is three threads past the nut.
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I was rebuilding the clutch in my car due to catastrophic failure, anyway I was after some specs for the clutch fork adjustment as I found a few
discrepancy, with no 100% guaranteed specs I called the clutch kit manufacture.
me "hello, I have 1 of your clutch kits, can you give me the specs on the pivot ball adjustment, the specs wasn't supplied with the kit "
the guy " you shouldn't need to adjust it"
me " no but my adjustment was wrong and has contributed to the failure of the old clutch"
the guy ( moment of silence) "............ just bolt the clutch in!"
me "I am sorry I need the measurement of the pivot ball"
the guy " (mumble mumble) hang on...... I'll get the book........ its says for the end of the clutch fork needs to be 39mm from the front of the
bell housing"
me "yes thats the end of the clutch fork, I need the pivot ball measurement"
the guy " yeah its 39mm"
me "no, thats not the same as the pivot ball measurement"
the guy " yes it is"
me "no it suppose to be 100 and something"
the guy " oh that ones, nope doesn't say in the book, just set it what ever works....the 39mm "
me " I can't use that measurement, I can't get the bell housing off even with a 1 foot beaker bar, I must use the pivot ball measurement"
the guy " just adjust it to the 39mm on the fork end"
me" but I can't, the bell housing wont come off, the bolts will break if I try any harder..... are you sure it doesn't state this messuremnt?"
the guy "no just that one"
me " ok no probs, thanks.... cya"
Useless!, so i ended using the specs from exedy's website which proved to be the correct 1.
I mean seriously :/ the manufacture which is here in Oz doesn't even supply installation instructions or specs nor support for their product. I must
say its and excellent clutch  but no support whats so ever.
There was some else in this circus of ringing around trying to get info who suggested that i should reuse my flywheel bolts thats are TTY and also
that even if there were too sort, 1.5 threads is all you need to hold the bolt at full strength
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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matberry
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| posted on September 26th, 2012 at 10:28 PM |
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Now, where were we.......
mmmm, a nice 2275. Price breakdown I don't know as I've not seen any paperwork. Scat crank, cam and rods, VW 043 heads, Mahle p & b kit, Empi
case, clutch & manifold & linkage kit.
Now remember the last pic of the head nut with all of 2 threads engaged, that was 3/4 side, so here is the other head, 1/2 side, and just so it
wasn't left out, it also got the same treatment.
Obviously 1 or 2 threads isn't enough thread to hold on the head, so #3 cylinder had the stud fail which cause this massive blow-by
I forgot one other shop (#4 for this engine and it's only 5000km old), after the fire the car was towed to a VW repair shop where it sat for a month.
The shop was asked to take care of the fire extinguisher powder that covered the engine as it's extremely corrosive and the owner was worried about
his expensive engine. Well they removed the carbs and put water down the cylinder creating this mess once it sat for a few weeks.
Here is a pic of the failed lifters
and centre main bearing very scored with copper starting to show
Silicone should NOT be used on case 1/2's. It holds the cases apart which prevents the case providing the correct bearing crush
you can't see it in the pic, but the owner was told he needed a Hi-torque starter as the new engine was tight to turn over.....that would have been
because the timing gears were so burred they bound even after being forced to run together for 5000km !!!!!!!!!
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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vlad01
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| posted on September 26th, 2012 at 10:37 PM |
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so what the hell is is even usable after all this? pretty much nothing? conrods maybe?
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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matberry
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| posted on September 26th, 2012 at 10:42 PM |
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I'll answer that once everything is checked properly.
More than the last job of similar fate.......but that's another story
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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psimitar
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| posted on September 27th, 2012 at 12:20 AM |
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Man I'd take $10k outta that builders hide. This is shocking!!! But not unusual these days.
I heard very reliably that a body shop that does high end vehicles couldn't be bothered to weld up the trim holes in a decklid but said that a bit of
filler would be perfectly OK. Wow, so it may look great for a while but after a few years at best you won't be so pleased with your expensive paint
job
Friend is having a house built and the builder dug the footings in the wrong place and now has to get new building permission cos the drawings given
to the customer weren't the ones submitted to the council. Awesome!!!
madness is in the eye of the beholder |
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vlad01
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| posted on September 27th, 2012 at 10:44 PM |
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sad world we life in now 
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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psimitar
Son of Jim - Creator of Good
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| posted on September 28th, 2012 at 12:45 AM |
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Vlad, you should watch Holmes Inspection on Foxtel 119. Now that's an eye opener
madness is in the eye of the beholder |
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vwo60
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| posted on September 28th, 2012 at 10:30 AM |
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Most of these people that hang a shingle outside there shop have never seen inside a Tafe, $100 a hour to get a great job done like this, to do that
job properly the average vw person cannot afford the time required to build a engine properly, i only farm out things like paint and panel and that's
another story, you only have to look at the welding that comes out of some places, I just looked a super bug a you person bought with a road worthy,
they had welded up the frame head and passed it, absolute rubbish. looked like they forgot to turn the gas on.
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